Selvage thread system

ABSTRACT

A system for manufacturing a scrim material reinforced by a plurality of yarns includes a yarn dispenser to support and space the plurality of yarns in a yarn pattern, a nipping roll including the scrim material for mating to the yarn pattern, forming the scrim, a guide coupled to the yarn dispenser and positioned within the yarn pattern, the guide providing a first retainer for maintaining the yarn pattern, and a selvage thread assembly extending from the guide and coupling the guide to the nipping roll. The selvage thread assembly includes a spindle and a selvage thread having a first end coupled to the spindle and a second end coupled to the nipping roll, the selvage thread positioned within the yarn pattern, providing a second retainer for maintaining the yarn pattern until the yarn pattern is mated to the scrim material.

BACKGROUND

The present invention relates generally to the field of scrim laying machines, and particularly to a selvage thread system for manufacturing reinforced scrim. Such reinforced scrim may be used in the manufacture of sailcloths, building materials, or other products requiring reinforced sheet material.

Conventional scrim laying machines typically include a fiber dispensing reel that rotates to form a pattern of fibers that comprises the reinforcing portion of the scrim. The fibers are fed from the fiber dispensing reel to a laminating device opposite the reel. The laminating device may include a film or web having an adhesive portion that pulls the fibers from the reel and onto the web, forming the scrim.

Typically, conventional scrim laying machines also include a screw, spring, or other guide near each edge of the fiber dispensing reel for guiding the fibers and maintaining the spacing of the fibers until stabilized by the supporting web. The guides are intended to maintain the spacing of the fibers until the fibers are bonded to the supporting web. However, in some cases, such as when there is limited space near the laminating device or when the width of the laminating device is wider than the width of the scrim being produced, the guides cannot be positioned close enough to the laminating device to maintain a particular pattern of fibers, and the pattern is more difficult to guide or control. In these cases, the scrim produced may not include the desired pattern of fibers, which may result in a higher scrap rate for the scrim product, thus increasing the cost to produce the scrim.

SUMMARY

An embodiment of the present disclosure relates to a system for manufacturing a scrim material reinforced by a plurality of yarns. The system includes a yarn dispenser to support and space the plurality of yarns in a yarn pattern, a nipping roll including the scrim material for mating to the yarn pattern, forming the scrim, a guide coupled to the yarn dispenser and positioned within the yarn pattern, the guide providing a first retainer for maintaining the yarn pattern, and a selvage thread assembly extending from the guide and coupling the guide to the nipping roll.

In this embodiment, the selvage thread assembly includes a spindle coupled to the yarn dispenser, and a selvage thread having a first end coupled to the spindle and a second end coupled to the nipping roll, the selvage thread positioned within the yarn pattern, providing a second retainer for maintaining the yarn pattern until the yarn pattern is mated to the scrim material.

Another embodiment of the present disclosure relates to an apparatus in a scrim forming system for maintaining a yarn pattern during manufacturing of a scrim. The apparatus includes a spindle, a selvage thread coupled to the spindle, a tip coupled to the selvage thread and configured to couple to a guide, a base coupled to the tip, and an arm removably coupled to the base. The selvage thread is configured to provide a retainer for maintaining a yarn pattern for a scrim.

Another embodiment of the present disclosure relates to a method for making a scrim. The method includes providing a yarn dispenser comprising a plurality of yarns spaced to form the yarn pattern, providing a nipping roll comprising a scrim material for mating to the yarn pattern, positioning a first guide within the yarn pattern and orienting the guide substantially perpendicular to the nipping roll, and providing a spindle coupled to the yarn dispenser and a selvage thread coupled to the spindle. The method also includes extending the length of the guide by routing the selvage thread from the spindle to the guide, routing the selvage thread to the nipping roll, and positioning the selvage thread within the yarn pattern, providing tension in the selvage thread by feeding the selvage thread into the nipping roll, and retaining and maintaining the yarn pattern by positioning the selvage thread at the inside edge of the yarn pattern.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, in which:

FIG. 1 is a perspective view of the scrim laying device of the present disclosure, according to an exemplary embodiment.

FIG. 2 is a schematic view of the scrim laying device of FIG. 1.

FIG. 3 is another perspective view of the scrim laying device of FIG. 1.

FIG. 4 is a close-up perspective view of a selvage thread assembly and a lead screw for a scrim laying device, according to an exemplary embodiment.

FIG. 5 is a close-up perspective view of a rotating creel, including spool holders for a selvage thread, according to an exemplary embodiment.

FIG. 6 is an isolated perspective view of the selvage thread assembly of FIG. 5.

FIG. 7A is a side view of a base for the selvage thread assembly of FIG. 5.

FIG. 7B is a top view of a base for the selvage thread assembly of FIG. 5.

FIG. 8 is top view of an arm for the selvage thread assembly of FIG. 5.

FIG. 9A is a perspective view of a tip for the selvage thread assembly of FIG. 5.

FIG. 9B is a side view of the tip of FIG. 9A.

FIG. 9C is a bottom view of the tip of FIG. 9A.

FIG. 10 is an isolated perspective view of a spool holder for a scrim laying device, according to an exemplary embodiment.

FIG. 11 is a perspective view of a selvage thread assembly and laminating machine, according to an exemplary embodiment.

DETAILED DESCRIPTION

Before turning to the figures, which illustrate the exemplary embodiments in detail, it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.

Referring to FIGS. 1-3, a scrim laying device 100 is shown, according to an exemplary embodiment. The scrim laying device 100 may be used to produce scrim (i.e. a material having a pattern of reinforcing fiber). In this embodiment, the scrim laying device 100 includes a yarn dispenser shown as a rotating creel 30. The rotating creel 30 includes a plurality of yarns 32 (e.g. threads, strings, fibers, etc.) positioned around the perimeter of the rotating creel 30. As the rotating creel 30 rotates, the plurality of yarns 32 form a cone or tube of yarns that is in motion perpendicular to the direction of a web 34 (e.g. film, sheet, etc.). The web 34 is positioned on a laminating machine 36 (i.e. scrim machine or scrim forming machine) having a nipping roll 42 (i.e. a powered roll used to press two sheets together to form the scrim). The cone of yarns is fed into a frame 38 (e.g. chain, etc.) for forming the cone of yarns into a pattern 28. The frame 38 may be shaped to produce a particular pattern. In an exemplary embodiment, the pattern of yarns 28 is in the shape of crossing diagonal lines, but another pattern can be used in other embodiments. The pattern of yarns 28 is fed into the laminating machine 36, where the pattern of yarns 28 is pulled by the nipping roll 42 and bonded (e.g. mated, stabilized, etc.) to the supporting web 34 to form a scrim.

Referring now to FIG. 4, a selvage thread assembly 10 for the scrim laying device 100 is shown, according to an exemplary embodiment. In this embodiment, a guide for the pattern of yarns 28 is shown as lead screw 18. The screw 18 is coupled to the frame 38 and positioned substantially perpendicular to the frame 38 and to the laminating machine 36 (shown in FIGS. 1-3). The screw 18 is located within the pattern of yarns 28 such that the screw 18 acts as a retainer for the pattern of yarns 28, establishing an outer perimeter for the pattern of yarns 28. The screw 18 is intended to maintain the spacing of the yarns to produce a particular pattern. In an exemplary embodiment, the pattern of yarns 28 rotates around the screw 18, moving laterally along the screw 18 and toward the end of the screw 18. The pattern of yarns 28 moves laterally past the end of the screw 18 to a selvage thread 44 forming the outer perimeter of the scrim.

Still referring to FIG. 4, the selvage thread assembly 10 is shown coupled to the frame 38. In this embodiment, the selvage thread assembly 10 includes selvage thread 44 routed through the frame 38, through the selvage thread assembly 10, and into the laminating machine 36. The nipping roll 42 of the laminating machine 36 is intended to maintain a tension in the selvage thread 44 as the yarns and thread 44 are formed into scrim. The selvage thread 44 is intended to extend the length of the guide, or screw 18, so that the pattern of yarns 28 is maintained within the scrim until the pattern 28 is stabilized by the supporting web 34. For example, a laminating machine 36 may have limited space in the area of the nipping roll 42, or the width of the nipping roll 42 may be wider than the width of the scrim being produced, making it difficult to position the screw 18 close to the nipping roll 42. In these instances, the selvage thread 44 adds a length to the guide, maintaining the pattern of yarns 28 within the scrim until the yarn and selvage thread 44 are enveloped into the scrim.

The selvage thread assembly 10 also includes a tip 16 that is coupled to the tip 40 of the screw 18. In exemplary embodiments the selvage thread 44 is routed through an opening 46 of the tip 16. In these embodiments, the selvage thread 44 is routed through the tip 16 such that the selvage thread 44 extends from the screw 18 and on the same axis as the screw 18 (i.e. substantially parallel to the screw 18 and substantially perpendicular to the laminating machine 36 and nipping roll 42). The selvage thread 44 is fed into the nipping roll 42, forming a second retainer for the pattern of yarns 28 and effectively extending the length of the screw 18. As the pattern of yarns 28 is fed into the laminating machine 36, the yarn moves laterally toward the tip 16 of the screw 18 to the nipping roll 42. The selvage thread 44 creates an outer perimeter for the scrim, maintaining the spacing of the yarn and the pattern of yarns 28 until the pattern 28 and the selvage thread 44 are stabilized (e.g. bonded, supported, restrained, engaged, etc.) by the supporting web 34. In some embodiments, the selvage thread assembly 10 may include more than one selvage thread 44 in order to provide a more stable perimeter as necessary. In an exemplary embodiment, the selvage thread 44 remains within the scrim, forming an inner perimeter for the scrim. However, in other embodiments the selvage thread 44 portion of the scrim is removed by trimming the edges before the scrim is used or sold. The selvage thread assembly 10 is shown in further detail in FIGS. 6-9. The pattern of yarns 28 being pulled off the screw (i.e. a first retainer) are supported (e.g. engaged, restrained, retained, etc.) by the selvage thread 44 extending (in tension) between the tip 16 and the nipping roll 42. Such support maintains the desired spacing of the pattern of yarns 28. Without the selvage thread 44, the pattern of yarns 28 tends to lose tension, resulting in a disruption of the intended pattern 28.

Referring now to FIG. 5, spool holders 20 are shown for the scrim laying device 100, according to an exemplary embodiment. In this embodiment, the scrim laying device 100 includes two spool holders 20, with one spool holder 20 positioned on each side of the rotating creel 30. The scrim laying device 100 may also include two selvage threads 44 (shown in FIG. 4), with a first end of each selvage thread 44 connected to a spool holder 20 and extending out to a second end that is routed through a selvage thread assembly 10. In this embodiment, the two selvage thread assemblies 10 are positioned on opposite sides of the frame 38 and aligned with respective spool holders 20. The selvage threads 44 are routed through the selvage thread assemblies 10 and fed into the nipping roll 42 such that the spacing of the yarn is retained on both sides of the frame 38, thus maintaining the desired pattern of yarns 28 until the yarn is stabilized by the supporting web 34 within the laminating machine 36. The spool holders 20 are configured to rotate, unraveling the selvage thread 44 as the thread 44 is pulled into the laminating machine 36, forming a scrim. The spool holders 20 are shown in further detail in FIG. 10.

Referring now to FIGS. 6-9, the selvage thread assembly 10 and its components are shown, according to an exemplary embodiment. In this embodiment, the selvage thread assembly 10 includes a base 12. The base 12 may be coupled to the frame 38 by locking assemblies (not shown). The base 12 is rectangular in shape and is sized and configured to be coupled to the frame 38 without interfering with the function of the scrim laying device 100. The base 12 is also configured to receive an arm 14. The arm 14 has a curved shape, extending out from the base 12 and curving to meet the tip 40 of the screw 18. The arm 14 is coupled to the base 12 by a quick release pin 48. In some embodiments, the selvage thread assembly 10 may include arms other than arm 14. In these embodiments, the arms may be replaced by removing the quick release pin 48. Arms of different sizes and lengths may be used to accommodate smaller or larger guides, and the arms may be of any shape or size as is necessary for the particular application.

The selvage thread assembly 10 also includes the tip 16, which is shown in further detail in FIG. 9. The tip 16 is coupled to the arm 14 and sized to receive the tip 40 of the screw 18. The tip 16 includes the opening 46 positioned on a side of the tip 16. The opening 46 is used for receiving and routing the selvage thread 44. The selvage thread 44 is routed through the tip 16 and out of opening 50 positioned on another side of the tip 16. The selvage thread 44 is routed from the opening 50 to the nipping roll 42, where the selvage thread 44 is mated (e.g. bonded, etc.) or otherwise coupled with the scrim. The tip 16 also includes an opening 52 for coupling the tip 16 to the screw 18. The opening 52 is sized and configured to receive the tip 40 of the screw 18, such that the screw 18 is able to rotate independently of the tip 16 and the selvage thread assembly 10.

Referring now to FIG. 10, a spool holder 20 is shown, according to an exemplary embodiment. The selvage thread assembly 10 may include the spool holder 20. In this embodiment, the spool holder 20 includes a spindle 22 for holding the selvage thread 44. The selvage thread 44 is wrapped around the spindle 22, and the spindle 22 is configured to rotate to release the selvage thread 44 as the thread 44 is fed into the nipping rolls 42 and stabilized by the supporting web 34 of the scrim (i.e. bonded with the scrim and coupled to the nipping roll 42, the pull of the rotating nipping roll 42 forming tension in the selvage thread 44). The spool holder 20 also includes a strut weldment 24 coupled to the spindle 22, and a bracket 26 coupled to the strut weldment 24. The bracket 26 couples the spool holder 20 to the rotating creel 30. The strut weldment 24 extends out perpendicular to the face of the bracket 26. The spindle 22 is coupled to an opposite end of the strut weldment 24 and extends perpendicularly from the strut weldment 24.

Referring now to FIG. 11, the selvage thread assembly 10 is shown coupled to the frame 38. In this embodiment, the selvage thread 44 is routed through the frame 38, through the selvage thread assembly 10, and into the laminating machine 36. The nipping roll 42 of the laminating machine 36 is intended to maintain a tension in the selvage thread 44 as the yarns and thread 44 are formed into scrim. The selvage thread 44 is intended to extend the length of the guide, or screw 18, so that the pattern of yarns 28 is maintained within the scrim until the pattern 28 is stabilized by the supporting web 34. For example, a laminating machine 36 may have limited space in the area of the nipping roll 42, or the width of the nipping roll 42 may be wider than the width of the scrim being produced, making it difficult to position the screw 18 close to the nipping roll 42. In these instances, the selvage thread 44 adds a length to the guide, maintaining the pattern of yarns 28 within the scrim until the yarn and selvage thread 44 are enveloped into the scrim.

The foregoing description of embodiments of the present invention have been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the present invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the present invention. The embodiments were chosen and described in order to explain the principles of the present invention and its practical application to enable one skilled in the art to utilize the present invention in various embodiments, and with various modifications, as are suited to the particular use contemplated.

The construction and arrangements of the selvage thread system, as shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention. The order or sequence of any process steps may be varied or re-sequenced according to alternative embodiments.

Various embodiments are described in the general context of method steps, which may be implemented in one embodiment by a program product including computer-executable instructions, such as program code, executed by computers in networked environments. Generally, program modules include routines, programs, objects, components, data structures, etc. that perform particular tasks or implement particular abstract data types. Computer-executable instructions, associated data structures, and program modules represent examples of program code for executing steps of the methods disclosed herein. The particular sequence of such executable instructions or associated data structures represents examples of corresponding acts for implementing the functions described in such steps.

The terms “coupled,” “connected,” and the like as used herein mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. 

1. A system for manufacturing a scrim material reinforced by a plurality of yarns, the system comprising: a yarn dispenser to support and space the plurality of yarns in a yarn pattern; a nipping roll comprising the scrim material for mating to the yarn pattern, forming the scrim; a guide coupled to the yarn dispenser and positioned within the yarn pattern, the guide providing a first retainer for maintaining the yarn pattern; a selvage thread assembly extending from the guide and coupling the guide to the nipping roll, the selvage thread assembly comprising: a spindle coupled to the yarn dispenser; and a selvage thread having a first end coupled to the spindle and a second end coupled to the nipping roll, the selvage thread positioned within the yarn pattern, providing a second retainer for maintaining the yarn pattern until the yarn pattern is mated to the scrim material.
 2. The system of claim 1, wherein the system comprises a first selvage thread assembly positioned to maintain the yarn pattern at a first side of the nipping roll, and a second selvage thread assembly positioned to maintain the yarn pattern at a second side of the nipping roll.
 3. The system of claim 1, wherein the selvage thread assembly comprises a plurality of selvage threads for maintaining the yarn pattern.
 4. The system of claim 1, wherein the selvage thread assembly comprises: a tip coupled to the selvage thread and coupled to the guide; a base coupled to the tip; and an arm removably coupled to the base.
 5. The system of claim 4, wherein the arm has a curved shape, extending from the base to meet the guide.
 6. The system of claim 5, further comprising a release pin for removing and replacing the arm.
 7. The system of claim 5, wherein the tip comprises a first opening for receiving the selvage thread and a second opening for routing the selvage thread to the nipping roll.
 8. The system of claim 1, wherein the guide is oriented substantially perpendicular to the nipping roll, and the selvage thread is positioned substantially perpendicular to the nipping roll and substantially parallel to the guide.
 9. The system of claim 1, further comprising: a frame coupled to the yarn dispenser and configured to form the plurality of yarns into the yarn pattern; wherein the selvage thread assembly is coupled to the frame.
 10. The system of claim 9, wherein the frame comprises a chain.
 11. The system of claim 1, wherein the selvage thread is mated to the scrim material and is formed within the scrim.
 12. An apparatus in a scrim forming system for maintaining a yarn pattern during manufacturing of a scrim, the apparatus comprising: a spindle; a selvage thread coupled to the spindle; a tip coupled to the selvage thread and configured to couple to a guide; a base coupled to the tip; an arm removably coupled to the base; and wherein the selvage thread is configured to provide a retainer for maintaining a yarn pattern for a scrim.
 13. The apparatus of claim 12, wherein the arm has a curved shape, extending from the base to meet the guide.
 14. The apparatus of claim 12, further comprising a release pin for removing and replacing the arm.
 15. The apparatus of claim 12, wherein the tip comprises a first opening for receiving the selvage thread and a second opening for routing the selvage thread out from the tip.
 16. The apparatus of claim 12, wherein the apparatus comprises a plurality of selvage threads for maintaining the yarn pattern.
 17. The apparatus of claim 12, wherein the selvage thread extend out from the tip substantially perpendicular to the base.
 18. The apparatus of claim 12, wherein the selvage thread forms a portion of the scrim.
 19. A method for making a scrim, the method comprising: providing a yarn dispenser comprising a plurality of yarns spaced to form the yarn pattern; providing a nipping roll comprising a scrim material for mating to the yarn pattern; positioning a first guide within the yarn pattern and orienting the guide substantially perpendicular to the nipping roll, providing a spindle coupled to the yarn dispenser and a selvage thread coupled to the spindle; extending the length of the guide by routing the selvage thread from the spindle to the guide, routing the selvage thread to the nipping roll, and positioning the selvage thread within the yarn pattern; providing tension in the selvage thread by feeding the selvage thread into the nipping roll; and retaining and maintaining the yarn pattern by positioning the selvage thread at the inside edge of the yarn pattern.
 20. The method of claim 19, further comprising: mating the selvage thread to the scrim material and forming the selvage thread within the scrim. 